Shipping container convertible into a display configuration

Abstract

A shipping container convertible into a display configuration at a point of sale comprises a top wall, a bottom wall, side walls and end walls all of which are foldably joined to one another to form an interior space to receive product having a predetermined height. Each of the respective side walls includes a respective pair of spaced apart slots formed therein. Each of the end walls includes a respective minor top flap being foldably joined thereof. The respective minor top flaps include a pair of locking tabs each of which is engaged with the corresponding slots. A headspace is formed within the interior space of the container so as to compensate for the height of the products when the container is flipped on its side for displaybility at the point of sale and permits a user to remove product from various layers of containers stacked upon one another.

Claims

1. A shipping container convertible into a display configuration at a point of sale comprising: a top wall, a bottom wall, two opposite side walls, and two end walls all of which being foldably joined on a single blank of material to form an interior space to receive product having a predetermined height, each of the side walls includes a respective pair of spaced apart slots formed therein; each of the end walls includes a respective Z-shaped column being foldably joined thereto wherein each Z-shaped column includes a pair of locking tabs adjacent to the opposite side walls, each locking tab being engaged with a corresponding slot in an adjacent side wall; and a major top flap that is foldably joined to one of the side walls, the major top flap folded at a right angle with respect to said one of the side walls and locked behind the Z-shaped columns to form a front display lip when the container is positioned for display of product located within the interior space by flipping the container on its side for a pallet or shelf display.

2. The container of claim 1 further comprising a tear away panel having a first major top flap, wherein said major top flap that is foldably joined to one of the side walls comprises a second major top flap, and a portion of one of the side walls defined by perforated lines of weakness extending diagonally on one of the side walls.

3. The container of claim 2 wherein the tear away panel is removed before the container is flipped on its side for a pallet or shelf display.

4. The container of claim 1 wherein each of the respective Z-shaped column is formed by a respective minor top flap that is divided by a plurality of fold lines in which upon folding onto itself forms the respective Z-shaped column that provides compression strength when the container is flipped on its sides for pallet or shelf display.

5. The container of claim 4 wherein each of the Z-shaped columns includes a size that is capable of being increased or decreased so as to obtain a container width that corresponds to a pallet footprint for shipping.

6. A shipping container in combination with a product and convertible into a display configuration at a point of sale comprising: a top wall, a bottom wall, a first side wall and a second side wall opposite from the first side wall, and two end walls all of which being foldably joined on a single blank of material to form an interior space to receive product having a predetermined height; a first major top flap foldably joined to the second side wall and a second major top flap foldably joined to the first side wall, wherein the first major top flap is removable and the second major top flap is located at a lower front side of a display opening for the container when the container is converted to a display configuration oriented in a position resting on the first side wall; each of the end walls includes a respective column being foldably joined thereto wherein the respective columns being supported by one of the side walls when the container is in the display configuration and wherein the respective columns is capable of being changed in size so as to obtain a container width that corresponds to a pallet footprint for shipping; a headspace defined between the opposite side walls within the interior space of the container so as to compensate for the height of the products when the container is flipped on its side and the first major top flap is removed for displaying at the point of sale and permits a user to remove product from various layers of containers stacked upon one another without hindrance; and each of the side walls includes a respective pair of spaced apart corresponding slots formed therein, wherein each of the respective columns includes a pair of locking tabs each of which is engaged with the corresponding slots on the side walls.

7. The container of claim 6 further comprising a tear away panel formed by the first major top flap and a portion of the second side wall defined by perforated lines of weakness extending diagonally onto the second side wall wherein the tear away panel is removed before the container is flipped on its side for a pallet or shelf display.

8. The container of claim 6 wherein each of the respective columns is formed by a respective minor top flap that is divided by a plurality of fold lines in which upon folding onto itself forms a respective Z-shaped column that provides compression strength when the container is flipped on its sides for pallet or shelf display.

9. The container of claim 1 wherein the front display lip includes an inward facing side facing toward the interior space and an opposite outward facing side engaged by the Z-shaped columns.

10. The container of claim 4 wherein each minor top flap forming a respective Z-shaped column comprises a first section folded at a right angle to a respective adjacent end wall at a first fold line, a second section folded toward the respective adjacent end wall at a second fold line, and a third section folded away from the respective adjacent end wall at a third fold line.

11. The container of claim 10 wherein the first, second, and third sections are successively folded upon each other and are spaced from an adjacent section to form the respective Z-shaped column.

12. The container of claim 8 wherein each minor top flap forming a respective Z-shaped column comprises a first section folded at a right angle to a respective adjacent end wall at a first fold line, a second section folded toward the respective adjacent end wall at a second fold line, and a third section folded away from the respective adjacent end wall at a third fold line.

13. The container of claim 12 wherein the first, second, and third sections are successively folded upon each other and are spaced from an adjacent section to form the respective Z-shaped column.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:

(2) FIG. 1 is an exploded top perspective view of a partially folded container in accordance to a first embodiment of the invention, showing products in position to be placed inside of the container;

(3) FIG. 2 is a top perspective view of the fully constructed container in FIG. 1 with the products disposed therein;

(4) FIG. 3 is an enlarged view of a portion of the container in FIG. 2 illustrating the manner in which the top minor flaps are locked-in to form columns that provide compression strength when the container is flipped on its side;

(5) FIG. 4 is a front perspective view of the container when a tear away panel is removed and the display opening is in an upwardly facing orientation;

(6) FIG. 5 is a front perspective view of the two stacked containers in accordance to the first embodiment of the invention, in its operative use position with the display opening in a forwardly facing orientation and wherein headspace is provided so that the products can be removed from all layers of the stacked containers;

(7) FIG. 6 is a plan view of a blank used in making the container in FIGS. 1-5 in accordance to the first embodiment of the invention;

(8) FIG. 7 is an exploded top perspective view of a partially folded container in accordance to a second embodiment of the invention, showing products in position to be placed inside of the container;

(9) FIG. 8 is a top perspective view of the partially folded container in FIG. 7 with the products disposed therein;

(10) FIG. 9 is a top perspective view of the fully constructed container in FIG. 8 with the enclosed products for shipment to a point of sale;

(11) FIG. 10 is a front perspective view of the container when a tear away panel is removed and the display opening in a display position;

(12) FIG. 11 is a front perspective view of the two stacked containers in accordance to the second embodiment of the invention in its operative use position wherein headspace is provided so that the products can be removed from all layers of the stacked containers;

(13) FIG. 12 is a plan view of a blank used in making the container in FIGS. 7-11 in accordance to the second embodiment of the invention;

(14) FIG. 13 is a top view of one of the containers in FIG. 5 illustrating the over-sizing the container with respect to the size of the products so as to form a headspace within the container; and

(15) FIG. 14 is a front perspective view of an exemplary container in accordance to the first embodiment of the invention in its operative use position wherein a headspace is provided so that the products can be removed the container without impediment.

DETAILED DESCRIPTION OF THE INVENTION

(16) While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated. In the present invention the use of prime character in the numeral references in the drawings directed to the different embodiment indicate that those elements are either the same or at least function the same. In addition, in accordance with the usual conventions regarding the illustration of blanks for paperboard or corrugated paperboard articles, and unless otherwise specified, broken or interrupted lines within the boundaries of a blank represent scores, perforations or other lines of weakness, and extended solid lines, on the interior of a blank represent cuts.

(17) FIG. 1 is an exploded top perspective view of a partially folded container 10 in accordance to a first embodiment of the invention, showing products P in a position to be placed in the interior 11 of the container 10. The container 10 comprises a parallelepiped having opposite side walls 12 and 14, end walls 16 and 18, and top and bottom walls 20 and 22, respectively. The bottom wall 22 is defined by major and minor bottom flaps as will be discussed hereinafter. A respective minor top flaps 24a and 24b foldably extends from the respective end walls 16 and 18 defined by respective fold lines 26, 28. Each of the respective minor top flaps 24a and 24b includes a respective pair of tabs 30a, 30b and 30c, 30d each of which extends from the free opposed side edges thereof. The respective minor top flaps 24a and 24b are formed uniquely so as to be folded to form columns or beams that provide much needed package compression strength when the container 10 is flipped on its side for pallet displaybility. Each of the respective minor top flaps 24a and 24b is divided by respective fold lines 32a, 32b and 32c, 32d so that upon folding onto itself forming a respective Z-shaped columns 34a, 34b as seen best in FIG. 5. To securely hold the respective Z-shaped columns 34a, 34b in place, the respective tabs 30a, 30b and 30c, 30d are inserted to respective slots 36a, 36b and 36c, 36d formed on respective side walls 12 and 14. Two of the slots 36a, 36b are formed on the corner of the side wall 12 and they are spaced apart from one another. Similarly, the other two slots 36c, 36d are formed on the corner of the side wall 14 and they are spaced apart from one another. Second major top flap 38 foldably extends from respective side wall 12 via respective fold line 42. It should be noted that the first major top flap 20 is also denoted the top wall 20 which is separated from the container 10 via along perforated lines of weakness 40 extending diagonally in the side wall 14 before it is placed on the pallet for shipping as will be discussed hereinafter. The second major top flap 38 is formed on the side wall 12 and is defined by the fold line 42. The second major top flap 38 is folded at the right angle with respect to the side wall 12 and being held in that position by the respective Z-shaped columns 34a, 34b. When the container 10 is in the display position, the major top flap 38 is a lip used to prevent the products P from sliding and falling from the interior space 11.

(18) FIG. 2 is a top perspective view of the fully constructed container in FIG. 1 with the products disposed therein. It should be noted that first the products are disposed in the interior space 11, then each of the respective minor top flaps 24a and 24b is folded onto itself forming the respective Z-shaped columns 34a, 34b and finally the respective tabs 30a, 30b and 30c, 30d are inserted to respective slots 36a, 36b and 36c, 36d as seen best in FIG. 3.

(19) FIG. 4 is a front perspective view of the container 10 when a tear away panel 44 is removed and the display opening is oriented in an upwardly facing position. The tear away panel 44 includes the first top major flap 20 and a portion of the side wall 14 defined by the perforated lines of weakness 40 extending diagonally in the side wall 14. The major top flap 20 and the portion of the side wall 14 are foldably joined to one another by fold line 43. After removing the tear away panel 44, the container 10 or the display shipper is flipped on its side for pallet displaybility.

(20) FIG. 5 is a front perspective view of the two stacked containers 10 in accordance to the first embodiment of the invention, in its operative use position with the display opening in a forwardly facing orientation. One of the advantages of the instant invention is that each of the stacked containers 10 permits a user to shop from any layer of the stacked containers since each container 10 includes a built-in headspace 50. As seen best in FIGS. 13 and 14, the built-in headspace 50 is formed by extending a width (W) of the interior space 11 so that the headspace 50 compensates for the height of the products when the container 10 is flipped on its side for displaybility at the point of sale. The width (W) is defined by the widths the bottom flaps and end walls.

(21) The container 10 is made of a single piece of formable material such as, without limitation, corrugated containerboard and/or paperboard material. The container 10 is a display shipper that manufactured on the existing RSC case erector, filler and sealer equipments. The container 10 or display shipper is then placed on a pallet to be used as a full pallet display at any retail store and/or a club store. The container 10 or the display shipper 10 is particularly constructed so that users can remove products P from any layers of the stacked containers on the pallet. The container 10 or the display shipper eliminates the whole current practice used to have RSC's cases filled with products and then shipped to a secondary warehouse to be un-packed, then re-packed into a display shipper that is manually set-up. In the current practice the original case is then thrown away or re-cycled which is a huge waste and/or costly. Some of particular features of the instant invention are, but not limited to, the strong multi-corner beams or columns 34a, 34b on front side of the container when the container 10 is in its operative use position with the display opening in a forwardly facing orientation and a built-in headspace 50 that permits product shopping from all layers of the stacked containers. In addition, the size of minor top flaps 24a, 24b and/or, in turn, multi-corner beams or columns 34a, 34b can be increased or decreased so that to obtain a desired container width that would optimize the pallet footprint for shopping.

(22) FIG. 6 is a plan view of a blank B1 used in making the container in FIGS. 1-5, 13 and 14 in accordance to the first embodiment of the invention. The blank B1 is preferably constructed from a single piece of formable material such as, without limitation, sheets of cellulose-based materials formed from cellulose materials such as wood pulp, straw, cotton, bagasse or the like. Cellulose-based materials used in this present invention come in many forms such as fiberboard, containerboard, corrugated containerboard and paperboard. The blank B1 is cut and scored, perforated or otherwise formed to include a plurality of panels that when assembled form container 10. In all FIGURES, cut lines are shown as solid lines, score lines as dashed lines, and lines of perforation as broken lines. A series of fold scores 29 in the blank B1 define a second side wall panel 14 at a first end of the blank B1, a first end wall panel 16 adjoining the second side wall panel 14, a first side wall panel 12 adjoining the first end wall panel 16 along an edge opposite that edge joined to the second side wall panel 14, and a second end wall panel 18 adjoining the first side wall panel 12 along the edge opposite the first end wall panel 16. A glue tab 46 is foldably joined to the edge of the second side wall panel 14 opposite the edge joined to the first end wall panel 16.

(23) Minor bottom flaps 48a and 48b are foldably joined to bottom edges of the end wall panels 16 and 18, respectively, and major bottom flaps 52a and 52b are foldably joined to bottom edges of the side wall panels 12 and 14, respectively.

(24) A first major top flap 20 is foldably joined to the second side wall panel 14 along the edge opposite the edge to which the major bottom flap 52b is attached. The length of the first major top flap 20 is smaller than the length of the second side wall panel 14. A second major top flap 38 is foldably joined to the first side wall panel 12 along the edge opposite the edge to which the bottom major flap 52a is attached. A first minor top flap 24a is foldably joined to the end wall panel 16 opposite the edge to which the minor bottom flap 48a is attached. A second minor top flap 24b is foldably joined to the end wall panel 18 opposite the edge to which the minor bottom flap 48b is attached. Two slots 36a, 36b are formed in the side wall panel 12 adjacent the second major top flap 38 and two slots 36c, 36d are formed in the side wall panel 14 adjacent the first major top flap 20. Respective locking tabs 30a, 30b project from the respective free side edges of the first minor top flap 24a and respective locking tabs 30c, 30d project from the respective free side edges of the second minor top flap 24b.

(25) The line of perforations 40 extends diagonally across second side wall panel 14 from both end of the fold line 43 to the semi-circular cut-outs 54, defining a triangular panel. The semi-circular cut-outs 54 defines a finger access opening to enable a user's finger to be inserted for pulling out on the panels to separate the tear away panel 44 along the lines of perforation.

(26) The steps for erecting the blank B1 to construct the container 10 by a folding machine are depicted in FIGS. 1-5. In FIG. 1 the container is shown opened up into a partially folded configuration and oriented with the top flaps up and the bottom flaps in folded position. Minor bottom flaps 48a, 48b are folded inwardly, followed by folding the two major bottom flaps 52a and 52b may be secured together in any suitable way, as by use of adhesive or other suitable fastener, but in the preferred embodiment a strip of tape T is applied over the two major bottom flaps 52a and 52b. Next, the major top flap 38 is folded inwardly at right angle with respect to the side wall 12 toward the interior space 11 and then each of the minor top flaps 24a, 24b is folded onto itself forming the respective Z-shaped columns 34a, 34b and inserted into the Respective locking tabs 30a, 30b, 30c, and 30d. The second major flap 38 is folded at the right angle with respect to the side wall 12 and being held in that position by the respective Z-shaped columns 34a, 34b. It will be noted that prior to converting the container 10 to its display configuration the tear away panel 44 is removed and the container 10 is flipped so that such the side wall 12 would be the bottom of the container 10. The loaded stacked containers 10 is placed on a pallet then shipped in the orientation shown in FIG. 5 to the point of the sale.

(27) A second embodiment of the invention is indicated generally at 54 in FIGS. 7-12. This embodiment of the invention is substantially similar to the first embodiment described hereinabove, except that the minor top flaps are substantially different in both of the embodiments.

(28) FIG. 12 is a plan view of a blank B2 used in making the container 54 in FIGS. 7-11 in accordance to the second embodiment of the invention. The blank B2 is preferably constructed from a single piece of formable material such as, without limitation, sheets of cellulose-based materials formed from cellulose materials such as wood pulp, straw, cotton, bagasse or the like. Cellulose-based materials used in this present invention come in many forms such as fiberboard, containerboard, corrugated containerboard and paperboard. The blank B2 is cut and scored, perforated or otherwise formed to include a plurality of panels that when assembled form container 10. A series of fold scores 29 in the blank B2 define a second side wall panel 14 at a first end of the blank B2, a first end wall panel 16 adjoining the second side wall panel 14, a first side wall panel 12 adjoining the first end wall panel 16 along an edge opposite that edge joined to the second side wall panel 14, and a second end wall panel 18 adjoining the first side wall panel 12 along the edge opposite the first end wall panel 16. A glue tab 46 is foldably joined to the edge of the second side wall panel 14 opposite the edge joined to the first end wall panel 16.

(29) Minor bottom flaps 48a and 48b are foldably joined to bottom edges of the end wall panels 16 and 18, respectively, and major bottom flaps 52a and 52b are foldably joined to bottom edges of the side wall panels 12 and 14, respectively.

(30) A first major top flap 20 is foldably joined to the second side wall panel 14 along the edge opposite the edge to which the major bottom flap 52b is attached. The length of the first major flap 20 is the same as the length of the second side wall panel 14. A second major top flap 38 is foldably joined to the first side wall panel 12 along the edge opposite the edge to which the major bottom flap 52a is attached. A first L-shaped minor top flap 56a is foldably joined to the end wall panel 16 opposite the edge to which the minor bottom flap 48a is attached. A second L-shaped minor top flap 56b is foldably joined to the end wall panel 18 opposite the edge to which the minor bottom flap 48b is attached. In the folded position, the respective first and second L-shaped minor top flap 56a, 56b is folded at the right angle with respect to the fold line 29 toward the interior space 11. The respective first and second L-shaped minor top flap 56a, 56b forms a respective L-shaped column when they are in folded position.

(31) The line of perforations 40 extends diagonally across second side wall panel 14 from both end of the fold line 43 to the semi-circular cut-outs 54, defining a triangular panel. The semi-circular cut-outs 54 defines a finger access opening to enable a user's finger to be inserted for pulling out on the panels to separate the tear away panel 44 along the lines of perforation.

(32) The steps for erecting the blank B2 to construct the container 54 are depicted in FIGS. 7-11. In FIG. 7 the container 54 is shown opened up into a partially folded configuration and oriented with the top flaps up and the bottom flaps in folded position. After the products P are disposed in the container 54, minor bottom flaps 48a, 48b are folded inwardly, followed by folding the two major bottom flaps 52a and 52b be secured together in any suitable way, as by use of adhesive or other suitable fastener, but in the preferred embodiment a strip of tape T is applied over the two major bottom flaps 52a and 52b. Next, the respective first and second L-shaped minor top flap 56a, 56b is folded at the right angle with respect to the fold line 29 toward the interior space 11, the first major top flap 20 is folded over at right angle with respect to the fold line 43 toward the interior space. And finally, the second major top flap 38 is folded over the respective first and second L-shaped minor top flap 56a, 56b and a strip of tape T is applied over the length of the second major top flap 38 and downwardly over the respective end wall panels 16 and 18. It will be noted that prior to converting the container 54 to its display configuration the tear away panel 44 is removed and the container 54 is flipped so that such the side wall 12 would be the bottom of the container 54. The loaded stacked containers 54 is placed on a pallet then shipped in the orientation shown in FIG. 11 to the point of the sale.

(33) Returning to FIGS. 7-11 and particularly to FIG. 7, which is an exploded top perspective view of a partially folded container 54 in accordance to a second embodiment of the invention in which showing the products P in a position to be placed in the interior 11 of the container 54. The container 54 comprises a parallelepiped having opposite side walls 12 and 14, end walls 16 and 18, and top and bottom walls 20 and 22. The bottom wall 22 is defined by major and minor bottom flaps as will be discussed hereinafter. A respective L-shaped minor top flap 56a and 56b foldably extends from the respective end walls 16 and 18 defined by respective fold lines 26, 28. Each of the respective L-shaped minor flaps 56a and 56b are formed uniquely so as to be folded to form columns that provide much needed package compression strength when the container 54 is flipped on its side for pallet or shelf display. Second major top flap 38 foldably extends from respective side wall 12 via fold lines 42. It should be noted that the first major top flap 20 is also denoted the top wall 20 which is separated from the container 54 via along perforated lines of weakness 40 extending diagonally in the side wall 14 before it is placed on the pallet for shipping as will be discussed hereinafter. The second major top flap 38 is formed on the side wall 12 and is defined by the fold line 42. The second major top flap 38 is folded at the right angle with respect to the side wall 12 and being held in that position in any suitable way, but in preferred embodiment a strip of tape T is applied over the length of the second major top flap 38 and downwardly over the respective end wall panels 16 and 18. When the container 54 is in the display position, the second major top flap 38 is a lip used to prevent the products P from sliding and falling from the interior space 11.

(34) FIGS. 8 and 9 is a top perspective view of the fully constructed container in FIG. 7 with the products disposed therein. It should be noted that the products are disposed in the interior space 11, then each of the respective minor top flaps 56a and 56b is folded at the right angle toward the interior space 11, the first top major flap 20 is overlapped on the minor top flaps 56a and 56b and then the second major top flap 38 is fold over both of the first major top flap 20 and the respective minor top flaps 56a and 56b.

(35) FIG. 10 is a front perspective view of the container 54 when a tear away panel 44 is removed and the display opening is oriented in a forwardly facing position. The tear away panel 44 includes the major top flap 20 and a portion of the side wall 14 defined by the perforated lines of weakness 40 extending diagonally in the side wall 14. The major top flap 20 and the portion of the side wall 14 are foldably joined to one another by fold line 43. After removing the tear away panel 44 the container 54 or the display shipper is placed a pallet for shipment to the point of sale.

(36) FIG. 11 is a front perspective view of the two stacked containers 54 in accordance to the second embodiment of the invention, in its operative use position with the display opening in a forwardly facing orientation. As noted above, one of the advantages of the instant invention is that each of the stacked containers 54 permits a user to shop from any layer of the stacked containers since each container 54 includes a built-in headspace 50. As seen best in FIGS. 13 and 14, the built-in headspace 50 is formed by extending a width (W) of the interior space 11 so that the headspace 50 compensates for the height of the products when the container 54 is flipped on its side for displaybility at the point of sale.

(37) The container 54 is made of a single piece of formable material such as, without limitation, corrugated containerboard and/or paperboard material. The container 54 is a display shipper that manufactured on the existing RSC case erector, filler and sealer equipments. The container 54 or display shipper is then placed on a pallet to be used as a full pallet display at any retail store and/or a club store. The container 54 or the display shipper 54 is particularly constructed so that users can remove products P from any layers of the stacked containers on the pallet. The container 54 or the display shipper eliminates the whole current practice used to have RSC's cases filled with products and then shipped to a secondary warehouse to be un-packed, then re-packed into a display shipper that is manually set-up. In the current practice the original case is then thrown away or re-cycled which is a huge waste and/or costly. Some of particular features of the instant invention are, but not limited to, the strong corner beams 56a, 56b on front side of the container when the container 54 is in its operative use position with the display opening in a forwardly facing orientation and a built-in headspace 50 that permits products P shopping from all layers of the stacked containers 54. In addition, the size of minor top flaps or corner beams 56a, 56b can be increased or decreased so that to obtain a desired container width that would optimize the pallet footprint for shopping. The columns are formed into Z-shaped and L-shaped since testing the container for compression strength denotes these two shapes significantly improve the compression strength.

(38) It should now be appreciated that the present invention provides a material-saving, quickly erected container or the display shipper especially useful in retaining, transporting variety of products to retail stores.

(39) Numerous modifications and variations on the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the accompanying claims, the invention may be practiced otherwise than as specifically described herein.

(40) While the invention has been described with reference to a preferred embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.